Extrusion International 1-2017

20 / 36

20 Extrusion International 1/2017 INDUSTRY 4.0
Step by step into the future
Veryearlyonmotan-colortronic recognisedtheopportunitiesof
anetworkedproductionand created thenecessary foundation.
motan already offers the possibilities for an intelligent, smart
factory with, for example, their CONTROLnet architecture
with integrated controls concept. With the development of an
OPC-UA interface (Open Platform Communications – Unified
Architecture), motan-colortronic was one of the first periphery
suppliers able to communicate with the processing machines
independent of manufacturer or platform.
The consistent modular set-up of the control components
also contributes to this by enabling the constant and trans-
parent networking of the manufacturer’s units with a pe-
riphery and communication network. motan-colortronic
is continually working on pilot projects together with dif-
ferent machine manufacturers to develop intelligent solu-
tions which support the processors in the optimisation of
their value added chain.
Synchronised production start
Up to now, the established practise has been to use weekly
timers to switch on the dryers and processing machines.
Independent of each other, the systems then wait for pro-
duction start – and use unnecessary energy during this
time. No consideration is taken if the production plan has
changed in the meantime.
In a Smart Factory with Industry 4.0, however, material
distribution and processing machines will start in coordina-
tion with each other.
Here, each processing machine choses “its” dryer, depend-
ing on the required throughput, and communicated the
time of production start. The material distribution does
everything else independently. This means that the drying
process starts automatically at the right time for enough
material of the required quality to be available at produc-
tion start. Machine andmaterial are both ready for produc-
tion at the same time and over-drying of the material is not
possible. The benefits are; improved productivity, resource
efficiency, and less energy consumption.
Dynamic and intelligent production monitoring
No one is immune from nasty surprises – interferences and
interruptions cannot be completely eliminated. This is why
the availability of material for the processing machine is
monitored through targeted information exchange even
during the process. Material shortages are displayed cen-
trally at the machine.
With a dynamic, intelligent response by the material dis-
tribution (in this case the dryer), the influence of an inter-
ference, wherever it may occur, on the flow of production
and the material can be minimised, if not completely elimi-
nated. For example, it may be worthwhile to lower the dry-
ing temperature and adjust the air flow in order to avoid
over-drying during longer production down-times. Due to
the constant comparison of piece numbers and remaining
production time, the drying system has all necessary infor-
mation to prevent material shortages.
Information regarding the current or remaining supply of
material, as well as the number of parts still to be produced,
is shown centrally on the processing machine’s display, in
order to offer the operating staff as much transparency as
possible regarding the current status of the entire process.
Co-ordinated production end
The material distribution knows the produced part num-
bers and remaining running time – the dryer knows that
only a few parts are left to be produced and adapts its op-
eration accordingly. This saves energy and prevents over-
drying of the remaining material. Additionally, the target-
ed running empty of the drying bin can be planned for the
end of production. For this, the required time until the bin
is empty is calculated in regards to the remaining number
of parts left to be produced. This saves energy for drying
and conveying, but also minimises return of material and
prevents material loss. The decentralised intelligence of
motan systems enables communication in all directions.
In practise, this means the operation and status data is ex-
changed between motan‘s material distribution systems
and the processing machines, the data is analysed by the
controls, and the required actions are started.
The goal, from the view of material distribution, is to en-
sure the required quantity and quality of available material
at the processing machine. For this, the processing process
must be viewed in its entirety in order to use the resources
at hand efficiently – for an economic production.